Fronius VR 1500-12 Operating Instructions Manual
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Fronius VR 1500-12 Operating Instructions Manual

Wirefeeder
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/ Battery Charging Systems /
VR 1530 -11 / -12 / - 22 / -30 / -KD
42,0426,0010,EN 005-08112013
Welding Technology
/ Solar Electronics
Operating Instructions
Spare Parts List
Wirefeeder

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Summary of Contents for Fronius VR 1500-12

  • Page 1 / Battery Charging Systems / Welding Technology / Solar Electronics Operating Instructions VR 1530 -11 / -12 / - 22 / -30 / -KD Spare Parts List Wirefeeder 42,0426,0010,EN 005-08112013...
  • Page 3 Read the manual carefully and you will soon be familiar with all the many great features of your new Fronius product. This really is the best way to get the most out of all the advantages that your machine has to offer.
  • Page 5 Safety rules DANGER! “DANGER!” indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury. This signal word is to be limited to the most extreme situations. This signal word is not used for property damage hazards unless personal injury risk appropriate to this level is also involved.
  • Page 6 General remarks Any malfunctions which might impair machine safety must be eliminated (continued) immediately - meaning before the equipment is next switched on. It’s your safety that’s at stake! Utilisation for The machine may only be used for jobs as defined by the “Intended purpose”. intended purpose The machine may ONLY be used for the welding processes stated on the only...
  • Page 7 Obligations of Before starting work, all persons to be entrusted with carrying out work with personnel (or on) the machine shall undertake to observe the basic regulations on workplace safety and accident prevention to read this operating manual particulary the sections on “Safety rules” and to sign to confirm that they have understood these and will comply with them.
  • Page 8 Protection for “Protective clothing” also includes: yourself and protecting your eyes and face from UV rays, heat and flying sparks with other persons an appropriate safety shield containing appropriate regulation filter glass (continued) wearing a pair of appropriate regulation goggles (with sideguards) behind the safety shield wearing stout footwear that will also insulate even in wet conditions protecting your hands by wearing appropriate gloves (electrically insula-...
  • Page 9 Hazards from The harmfulness of the welding fumes will depend on e.g. the following noxious gases components: and vapours the metals used in and for the workpiece (continued) the electrodes coatings cleaning and degreasing agents and the like For this reason, pay attention to the relevant Materials Safety Data Sheets and the information given by the manufacturer regarding the components listed above.
  • Page 10 Hazards from Do not loop any cables or other leads around your body or any part of your mains and weld- body. ing current (continued) Never immerse the welding electrode (rod electrode, tungsten electrode, welding wire, ...) in liquid in order to cool it, and never touch it when the power source is ON.
  • Page 11 Stray welding When using current supply distributors, twin head wire feeder fixtures etc., currents please note the following: The electrode on the unused welding torch/ (continued) welding tongs is also current carrying. Please ensure that there is sufficient insulating storage for the unused welding torch/tongs. In the case of automated MIG/MAG applications, ensure that only insulated filler wire is routed from the welding wire drum, large wirefeeder spool or wirespool to the wirefeeder.
  • Page 12 EMI Precautions Electromagnetic fields may cause as yet unknown damage to health. Effects on the health of persons in the vicinity, e.g. users of heart pace- makers and hearing aids Users of heart pacemakers must take medical advice before going anywhere near welding equipment or welding workplaces Keep as much space as possible between welding cables and head/ body of welder for safety reasons...
  • Page 13 Particular danger Risk of scalding from accidental discharge of hot coolant. Before unplugging spots the connectors for coolant forward flow and return flow, switch off the coo- (continued) ling unit. Observe the information on the coolant safety data sheet when handling coolant.
  • Page 14 Danger from Shielding-gas cylinders contain pressurized gas and may explode if they are shielding-gas damaged. As shielding-gas cylinders are an integral part of the overall cylinders welding outfit, they also have to be treated with great care. Protect shielding-gas cylinders containing compressed gas from excessive heat, mechanical impact, slag, naked flames, sparks and arcs.
  • Page 15 Safety precauti- Before transportation, completely drain any coolant and dismantle the ons at the instal- following components: lation site and Wire feed when being Wire wound coil transported Gas bottle (continued) Before commissioning and after transportation, a visual check for damage must be carried out.
  • Page 16 Preventive and With parts sourced from other suppliers, there is no certainty that these corrective main- parts will have been designed and manufactured to cope with the stressing tenance and safety requirements that will be made of them. Use only original spares and wearing parts (this also applies to standard parts).
  • Page 17 Data security The user is responsible for the data security of changes made to factory settings. The manufacturer is not liable, if personal settings are deleted. Copyright Copyright to this instruction manual remains the property of the manufacturer. The text and illustrations are all technically correct at the time of going to print.
  • Page 18 ud_fr_st_sv_00467 022013...

  • Page 19: Table Of Contents

    Every time before starting up ......................... 19 Final disposal ............................19 Technical data ............................. 20 VR 1530-12 ............................20 VR 1530-11 ............................20 VR 1530-22 ............................21 VR 1530-30 ............................21 VR 1530-KD20 ............................22 Spare Parts List Circuit diagram Fronius Worldwide...

  • Page 20: General Remarks

    A matching version of the VR 1530 is available for each version of the main wirefeeder VR 1500: VR 1500-11: VR 1530-11 (11 m/min) (433.07 ipm.) VR 1500-12: VR 1530-12 (12 m/min) (472.44 ipm.) VR 1500-22: VR 1530-22 (22 m/min) (866.14 ipm.) VR 1530-30: VR 1530-30 (30 m/min) (1181.10 ipm.) VR 1530-KD: The VR 1530-KD is available in conjunction with the KD 7000 cold-wire feeder.

  • Page 21: System Requirements

    VR 1500 robot wirefeeder combined with VR 1530-22 unreeling-type wirefeeder (1) TPS 5000 power source, with: (10) Wirefeed hose (from the VR 1530 to the VR 1500) Software update from the Fronius (11) Unreeling-type wirefeeder control databank cable Enhanced motor supply: 55 V / 8 A...

  • Page 22: Applicational Example: Vr 1530-11/-12/-30 Used As An Unreeling-Type Wirefeeder

    VR 1500 robot wirefeeder combined with VR 1530-22 unreeling-type wirefeeder (1) TPS 5000 power source, with: (10) Wirefeed hose (from the VR 1530 to the VR 1500) Software update from the Fronius (11) Unreeling-type wirefeeder control databank Enhanced motor supply: 55 V / 8 A...

  • Page 23: Warning Notices Affixed To The Machine

    Warning notices The wire feeder comes with extra warning labels affixed to the unit. The warning labels affixed to the must NOT be removed or painted over. The symbols warn against incorrect operation. machine Incorrect operation can cause serious personal injury and damage to property. Do not use the functions described here, until you have read and under- stood all of the following documents: these Operation instructions...

  • Page 24: Controls And Connection Points

    Controls and connection points General remarks Warning! Operating the equipment incorrectly can cause serious injury and damage. Do not use the functions described here until you have read and completely understood the whole of the “Operating Instructions” manuals for both the wirefeeders and the power source. VR 1530 -11 / -12 / -22 / - 30 (10)

  • Page 25: Vr 1530-Kd20

    VR 1530-KD20 (11) (12) (13) (10) (14) (15) Fig.6 View of wire inlet section Fig.7 View of wire outlet section No. Function (1) Blanking cap (2) Blanking cap (3) Blanking cap (4) Blanking cap (5) KD 7000 connection jack (CPC 37-pole) (6) Blanking cap (7) Wire infeed tube (8) Blanking cap...

  • Page 26: Wire-Inching Sequence When The Welder Presses And Holds The Feeder Inching Button

    Wire-inching To facilitate exact positioning of the welding wire, the following sequence is possible sequence when when the welder presses and holds the feeder inching button: the welder pres- ses and holds Important! The sequence described here does not apply to the wire-retract button. the feeder in- ching button CAUTION! There is a risk of injury while the lid is open for maintenance or...

  • Page 27: Putting The Unit Into Service

    Putting the unit into service Utilisation for WARNING! Operating the equipment incorrectly can cause serious injury and intended purpose damage, as can any work that is not carried out correctly. only Before putting the unit into service for the first time, read the “Safety rules” The VR 1530 wirefeeder may ONLY be used in MIG/MAG welding, as part of a suitably configured installation.

  • Page 28: Ready-Drilled Holes

    Ready-drilled holes (.32 in.) (.32 in.) 21.5 mm 280 mm 21.5 mm (.32 in.) (.85 in.) (11.03 in.) (.85 in.) Fig.11 Hole-pattern on the baseplate of the VR 1530 21.5 mm (.85 in.) 280 mm (11.03 in.) (.32 in.) (.32 in.) (.32 in.) (.32 in.) (.32 in.)

  • Page 29: Mounting The Wirefeed Hoses

    Mounting the wirefeed hoses Safety Warning! Work that is not carried out correctly can cause serious injury and damage. Before putting the unit into service for the first time, read the “Safety rules” Caution! There is a risk of injury while the lid is open for maintenance or retooling work to be carried out.

  • Page 30: Inserting / Changing The Feed Rollers

    Inserting / changing the feed rollers General remarks In order to achieve optimum wire travel, the feed rollers must be suitable for the diame- ter and alloy of the wire to be welded. USA wirefeeders In the USA, all wirefeeders are delivered without feed rollers. The feed rollers must be inserted into the wirefeed unit before it is started up for the first time.

  • Page 31: Feeding In The Welding Wire

    Feeding in the welding wire Insulated routing WARNING! Risk of serious injury and material damage or an inferior weld as of welding wire the result of earth contact or short-circuit of an uninsulated welding wire. In the to wirefeeder case of automated applications, ensure that only insulated welding wire is routed from the welding wire drum, large wirefeeder spool or wirespool to the wirefeeder (e.g.

  • Page 32: Feeding In The Welding Wire

    Feeding in the Open the clamping devices and welding wire pressure levers on the VR 1500 and (continued) the VR 1530 VR 1500 VR 1530 CAUTION! Risk of damage to wirefeeding hose and welding torch from sharp end of filler wire.

  • Page 33: Setting Contact Pressure

    Setting contact NOTE! Adjust the contact pressure in such a way that the welding wire is not pressure deformed, but is nevertheless transported properly. Contact pressure HR Guideline values Aluminium 3,5 - 4,5 Steel 3 - 4 CrNi 3 - 4 Feed rollers: HR = Half-round TR = Trapeze...

  • Page 34: Calibrating Push-Pull Unit

    Calibrating push-pull unit General remarks Important! Calibration of the push-pull unit is not necessary for the VR 1530-KD unree- ling wire-feed unit. The VR 1530 must be calibrated prior to each initial start-up and after each wire-feed unit software update. If the VR 1530 is not calibrated, the standard parameters will be used - which may result in the welding result being unsatisfactory.

  • Page 35: Troubleshooting

    Troubleshooting General remarks The following section gives you an overview of the possible causes of errors in connection with the VR 1530, and of steps you can take to remedy the problem. For detailed information on the causes of, and remedies for, errors in connection with wirefeeding in general, please refer to the operating instructions of your power source.
  • Page 36 VR 1530 error EFd | 9.1 diagnostics Cause: External supply voltage: The supply voltage has dropped below the (continued) tolerance range Remedy: Check the external supply voltage EFd | 9.2 Cause: External supply voltage: The supply voltage has risen above the tolerance range Remedy: Check the external supply voltage...

  • Page 37: Care, Maintenance And Disposal

    Care, maintenance and disposal General remarks Under normal operating conditions, the VR 1530 needs only a minimum of care and maintenance. However, to ensure continued trouble-free operation of your unreeling- type wirefeeder for years to come, there are a few basic points that you should observe. Every time before Inspect the VR 1530, interconnecting cable and earth connection for any signs of starting up...

  • Page 38: Technical Data

    4-roller drive, water-cooled electric motor with shrunk-on-disc rotor Option Extra fan for the power electronics Max. shielding-gas pressure 7 bar (101 psi.) Coolant Original Fronius coolant Max. coolant pressure 6 bar (87 psi.) VR 1530-12 Supply voltage (from the power source) 55 V DC...
  • Page 39 Weight - without optional extras 5 kg (11 lb.) Drive 4-roller drive Max. shielding-gas pressure 7 bar (101 psi.) Coolant Original Fronius coolant Max. coolant pressure 6 bar (87 psi.) VR 1530-30 Supply voltage (from the power source) 55 V DC Rated current Wire diameter 0,8 - 1,6 mm (.03 - .06 in.)

  • Page 40: Vr 1530-Kd20

    345 / 160 / 220 mm (13.59 / 6.3 / 8.67 in.) Weight - without optional extras 5 kg (11 lb.) Type of drive 4-roller drive Max. shielding-gas pressure 7 bar (101 psi.) Coolant Original Fronius coolant Max. coolant pressure 6 bar (87 psi.)

  • Page 41: Spare Parts List

    Ersatzteilliste Schaltplan Spare Parts List Circuit Diagram Liste de pièces de rechange Schéma de connexions Lista parti di ricambio Schema Lista de repuestos Esquema de cableado Lista de peças sobresselentes Esquema de conexões Onderdelenlijst Bedradingsschema Reservdelsliste Koblingsplan Seznam náhradních dílù Schéma zapojení...
  • Page 42 VR 1530-22 4R 4,045,921 VR 1530-KD 4R Z 4,045,867 4,100,257,U 42,0407,0500 42,0407,0501 BE2,0200,9691 BE2,0200,9905 - KD 42,0405,0269 BE2,0201,1568 44,0001,1255 - Z,10m/min,KD 44,0001,1260 - 22m/min BE2,0200,9699 BE2,0201,1567 43,0002,0217 42,0406,0224 BE2,0200,9906 43,0003,0256 43,0003,0584 42,0400,0183 43,0002,0079 BE2,0200,9693 - KD 42,0409,3015 VR 1530 Ersatzteilliste / Spare parts list / Listes de pièces de rechange / Lista de repuestos / Lista de pecas sobresselentes / Lista dei Ricambi el_fr_st_dv_00691 012007...
  • Page 43 VR 1530-11 4R 4,045,919 VR 1530-12 4R 4,045,920 VR 1530-30 4R 4,045,922 BE2,0201,1374 BE2,0201,1376 44,0001,1269 - 30m/min 44,0001,1271 - 12m/min 44,0001,1312 - 11m/min 40,0001,0012 - * 42,0409,3030 42,0407,0063 BE2,0200,9906 42,0405,0189 42,0405,0186 - RED 42,0405,0187 - BLACK 44,0001,1145 VR 1530 Ersatzteilliste / Spare parts list / Listes de pièces de rechange / Lista de repuestos / Lista de pecas sobresselentes / Lista dei Ricambi el_fr_st_dv_00691 012007...
  • Page 44 Motorplate 42V 4R 42,0400,0123 42,0405,0116 42,0407,0098 42,0404,0264 BF2,0404,0340 - yellow 42,0409,2106 32,0405,0112 32,0405,0113 42,0405,0117 - PE 42,0200,9352 - CuZn 42,0200,7767 t o r t o r 42,0405,0120 42,0300,2162 44,0001,1203 42,0407,0077 42,0407,0503 42,0100,0333 - PE 42,0406,0034 42,0001,3481 - Fe 22,0405,0114 42,0405,0119 BF2,0201,1345 Motorplate 42V 4R Ersatzteilliste / Spare parts list / Listes de pièces de rechange / Lista de repuestos / Lista de pecas sobresselentes / Lista dei Ricambi...
  • Page 45 Motorplate 42V 4R Ersatzteilliste / Spare parts list / Listes de pièces de rechange / Lista de repuestos / Lista de pecas sobresselentes / Lista dei Ricambi el_fr_st_mp_01220 012012...
  • Page 46 Motorplate 42V 4R Ersatzteilliste / Spare parts list / Listes de pièces de rechange / Lista de repuestos / Lista de pecas sobresselentes / Lista dei Ricambi el_fr_st_mp_01220 012012...
  • Page 47 Motorplate 42V 4R Ersatzteilliste / Spare parts list / Listes de pièces de rechange / Lista de repuestos / Lista de pecas sobresselentes / Lista dei Ricambi el_fr_st_mp_01220 012012...
  • Page 48 VR 1530...
  • Page 49 VR 1530-KD...
  • Page 50 FRONIUS INTERNATIONAL GMBH Froniusplatz 1, A-4600 Wels, Austria Tel: +43 (0)7242 241-0, Fax: +43 (0)7242 241-3940 E-Mail: sales@fronius.com www.fronius.com www.fronius.com/addresses Under http://www.fronius.com/addresses you will find all addresses of our Sales & service partners and Locations. ud_fr_st_so_00082 012011...

This manual is also suitable for:

Vr 1500-22Vr 1500-11Vr 1500-30Vr 1500-kd

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